Additive Manufacturing Process Overview - Wilson...

© David Rosen, Georgia Institute of Technology, 2014 A

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Additive Manufacturing Process Overview

David Rosen School of Mechanical Engineering

Georgia Institute of Technology Atlanta, GA 30332

[email protected]


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Additive Manufacturing Processes

1D Scanning

1D Parallel

2D Area-Filling

Pattern Energy Vat Photopolym. Powder Bed Fusion Electrochemical Deposition

Mask-Projection VP Sheet Lamination

Pattern Material Material Extrusion Material Jetting Binder Jetting

Thermal Spray

Pattern both Material & Energy

Directed Energy Deposition


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Industries using RP 2013


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AM Process Types ASTM Standard Industry Names Vendors Vat Photopolymerization Stereolithography 3D Systems,

EnvisionTEC, FormLabs Powder Bed Fusion Selective Laser

Sintering, Laser Melting, Electron-Beam Melting

3D Systems, EOS, ARCAM, Renishaw

Material Extrusion Fused Deposition Modeling

Stratasys, 3D Systems, Printrbot, etc.

Material Jetting MultiJet Modeling, PolyJet

Stratasys, 3D Systems, Sanders

Binder Jetting 3D Printing 3D Systems, Ex One, VoxelJet


Laser Engineered Net Shaping, Direct Metal Deposition

Optomec, DM3D, Sciaky, Insstek

Sheet Lamination Laminated Object Manufacturing, Ultrasonic Consolidation

MCor Technologies, CAM-LEM, Fabrisonic, Solido


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1D Scanning

1D Parallel

2D Area-Filling




Thermal Spray




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Vat Photopolymerization StereoLithography (SLA) Process Characteristics

+ 3D Systems - inventor + UV laser solidifies liquid

photopolymer in layers using a scanning system

+ Liquid is replenished and leveled between layers

+ Parts require support structures

+ Completed parts require cleaning and UV or Thermal post curing

Related Technologies + DMEC/Sony, CMET, EnvisionTec,

FormLabs, Asiga, Carima, DWS


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Stereolithography - SLA Machine Cost Build Size Laser

SLA-250/50 $150K 10”x10”10” HeCd

SLA Viper $180K 10”x10”10” Nd:YVO4

SLA-5000 $480K 20”x20”x24” Nd:YVO4

SLA-7000 $500K 20”x20”x24” Nd:YVO4

iPro 8000 ~$500K 650x750x550mm Nd:YVO4

iPro 9000XL ~$800K 1500x750x550mm Nd:YVO4


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Powder Bed Fusion (PBF) Selective Layer Sintering (SLS) Process Characteristics

+ C02 laser fuses thermoplastics powders in layers using a computer controller scanning system

+ Powder is replenished and the next layer is scanned

+ Powder temperature is maintained near melting point to aid fusion and minimize distortions

+ Supports may be used

Vendors + 3D Systems, EOS GmbH,

Arcam, SLM Solutions, Renishaw, Concept Laser


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Selective Laser Sintering - SLS • Product(s): Sinterstation 2500, HiQ, Pro 140, Pro 230 • Units sold total: ~600. $310 - 800K • Energy Source: 100 Watt CO2 Lasers • Materials: DuraForm (nylon), DuraForm GF (glass-

filled nylon), DuraForm EX (elastomer).


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Metal Powder Bed Fusion

Vendor Models Laser/Power Source

EOS GmbH M280, M290, M400

Yb-fibre laser 200W, 400W, 1kW

SLM Solutions 125HL, 280HL, 500HL

100W, 200W, 400W, 1kW, 2x400W, 2x1kW

Concept Laser M1, M2 Cusing, X line 1000R

Fibre 200, 400, 1000W

Renishaw AM250 Fibre 200W, 400W Phenix System (3D Systems)

ProX 100, 200, 300

Fibre 50W, 300W, 500W

Arcam Q10, Q20, A2X E-beam 3.5kW

Oak Ridge Nat’l Labs Lonnie Love

EOSINT M280


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1D Scanning

1D Parallel

2D Area-Filling




Thermal Spray




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Material Extrusion Fused-Deposition

Modeling (FDM) Process Characteristics

+ A heated thermoplastic filament is extruded from a capillary die

+ Parts chamber is often heated to minimize stresses and deformation

+ Required support structures + Cleanup required No post

processing

Stratasys Corp., many small companies selling table-top machines


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Material Extrusion Machine Cost Build Size Materials

Dimension $25 - 33K 10”x10”x12” ABS

uPrint $14 – 19K 8”x6”x6” ABS

Maxum $250K 24”x20”x24” ABS, MABS

Titan $190K 14”x16”x16” ABS, MABS, PC, PC blends, Polyphenylsulfone

250mc $45K 10”x10”x12” ABS

900mc $400K 36”x24”x36” ABS, MABS, PC, PPSF, Ultem

Materials(model) Cost/spool or cartridge

$250 – 300 for a spool of material


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Material Jetting

3D Systems, Solidscape, Stratasys

Process Characteristics • Nozzles jet beads of wax or

photopolymer. • As easy to use as a network

printer. • Fast and inexpensive. • Extensive support structures

needed.

Eden 250 from Objet Geometries


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Material Jetting Machine Cost Build Size Materials ProJet 3510 $60-86K 12”x8”x8” acrylate photopolymer ProJet 5000 $160K 22”x15”x12” acrylate photopolymer ProJet 3510 CP $74-86K 12”x8”x8” wax T66BT2 $40K 12”x6”x6” wax T612BT2 $50K 12”x6”x6” wax Objet30 $32-43K 12”x8”x6” acrylate photopolymer Eden350V $135K 14”x14”x8” acrylate photopolymer Eden500V $170K 20”x16”x8 photopolymer Objet500 Connex3 $330K 20”x16”x8 photopolymer (many mat’ls)

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Binder Jetting

Related Technologies + Ex One, VoxelJet.

Z Corporation (3D Systems) Process Characteristics • Print head deposits binder into

vat of powder. • Powder recoating is similar to

SLS. • As easy to use as a network

printer. • Fast and inexpensive. • Fragile and limited accuracy

– good infiltrants available

Powder Supply

Build Vat

Roller Print-Head


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Binder Jetting Machine Cost Build Size Colors Materials

ProJet 160 $16.5K 9.3”x7.3”x5” white Starch and plaster powders,

ProJet 460Plus $45K 8”x10”x8” 2.8M colors binders, and infiltrants

ProJet 660Plus $69K 10”x15”x8” 6M colors "

ProJet 860Pro $114K 20”x15”x9” "

Materials Cost

$0.30 – 1.60 per cubic inch of material

ProJet 460Plus


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Binder Jetting Machine Cost Build Size Materials

X1-Lab $145K 1.5”x2.3”x1.3” steel, copper, tungsten, nickel alloys; dental alloys

M-Flex $450+K 16”x10”x10” same

M-Print $950+K 31.5”x20”x16” same

S-Print $950+K 30”x15”x16” Foundry sand

S-Max $1,600+K 70”x39”x27” Foundry sand

Machines

Prices are for the base system; many options are available.

M-Print


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Sheet Lamination Process Characteristics

+ A CO2 laser cuts thin sheets of material into desired cross-sections

+ Process is tuned to precisely cut to sheet thickness

+ Material is thermally fused to the previous layer using a heated roller

+ Diced material is removed to uncover completed parts

Helisys (out of business, 1999). Cubic Technologies is renamed company.

Related Technologies + Cubic Technologies, Sparx, Kira,

MCor Technologies, Fabrisonics


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• Model: Matrix, Iris • $22 – 55k • Iris: Colors: 1M+,

5760x1440x508 dpi resolution • Material: copy paper

MCor Technologies


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Ultrasonic Consolidation • Process Characteristics

– Uses sonic welding to fuse aluminum strips to one another to add a layer.

– Machines contours of layers (3 axis machine tool). – Titanium alloys also. – Can embed components - fiber optics for sensing.

• Solidica, Inc.; Fabrisonics


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Ultrasonic Consolidation

Sonotrode rotates & traverses left to right to consolidate work-piece

Anvil holds work-piece in place

Pneumatic cylinder applies clamping force (138-241kPa)

Oscillation amplitude 6.5-14.5µm

Transducer

Traverse speed: static to 77mm/s

Fabrisonic SonicLayer 4000


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1D Scanning

1D Parallel

2D Area-Filling




Thermal Spray




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Directed Energy Deposition Laser Engineered Net Shaping

(LENS) Optomec, developed at Sandia

Process Characteristics • Direct metal fabrication using laser

cladding process. • 550W and 1000W Nd:YAG lasers. • Materials: 316 and 304 stainless

steels, H13 tool steel, nickel-based superalloys such as Inconel 625, 690, and 718, 2024 aluminum, and Ti-6Al-4V titanium alloy .

• 5-axis deposition head available.

Related Technologies • DM3D, Sciaky

Optomec 850


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Directed Energy Deposition DM3D, developed at University of

Michigan Process Characteristics • Direct metal fabrication using laser

cladding process. • 5 kW CO2 laser. • Build volume of 60x20x18 inches. • Materials: Claims to be able to deposit

wide variety of stainless steels, tool steels, nickel-based superalloys, and other superalloys.

• 5-axis deposition head available.

Related Technologies • Optomec, AeroMet

DMD 5000


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AeroMet Process Characteristics • Direct metal fabrication of titanium and

alloys using laser cladding process. • 18 kW CO2 laser. • Build envelope of 10x10x3 feet. • Materials: titanium alloys (Ti-6Al-4V). • 5-axis deposition head. • Only acts as a service bureau • Out of business in 2005, but

reorganizing…

Related Technologies • Optomec, POM Group


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AM Physical Principles

Thermal Chemical Ultrasonic Consolidation Melting Powder (SLS, SLM,

LENS, DMD) Photopolymerization Liquid

photopolymer (SL) Ultrasonic Welding

Metal sheets

Filament (FDM) Vapor Deposition Gaseous reagents (LCVD)

Coating (LOM) Electrochemical Deposition

Dissolved Metal Ions

Depositing Liquid Droplets - freeze as part (MJM) - freeze as binder (3DP)

Spraying Liquid Droplets


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Summary • Overview of additive manufacturing

processes and machines.

• Classified processes according to material of energy patterning vs. dimensionality of deposit.

• Classified physical principles.

• Next: Manufacturing process background.


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Additive Manufacturing Process Overview - Wilson...

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